Transporting apparatus for discrete sheets into envelopes and related methods

ABSTRACT

An apparatus transports a discrete paper or film object in a machine direction for insertion into an envelope. A guide assembly of the apparatus includes opposed first and second channels facing one another for guiding the object in the machine direction, with the channels extending upwardly to thereby define an uphill path of travel for the object. A drive apparatus includes engaging elements for moving the object along the first and second channels. At least one support element holds the object against the guide assembly.

CROSS-REFERENCE

This application is generally related to the following co-pending U.S.patent applications: Ser. No. ______ (Attorney Docket No. KERI-05),entitled “Apparatus for Guiding and Cutting Web Products and RelatedMethods;” Ser. No. ______ (Attorney Docket No. KERI-06), entitled“Envelope Conveying and Positioning Apparatus and Related Methods;” Ser.No. ______ (Attorney Docket No. KERI-07), entitled “Inserting Apparatusfor Discrete Objects into Envelopes and Related Methods;” Ser. No.______ (Attorney Docket No. KERI-09), entitled “Conveying Apparatus forEnvelopes and Related Methods;” and Ser. No. ______ (Attorney Docket No.KERI-10), entitled “Transporting Apparatus for Web Products and RelatedMethods”, all being filed on even date herewith and expresslyincorporated herein by reference in their entirety.

TECHNICAL FIELD

The present invention generally relates to converting equipment and,more particularly, to apparatus for converting paper into sheets,collating and automatic envelope stuffing operations.

BACKGROUND

Converting equipment is known for automatically stuffing envelopes. Suchequipment may include components for feeding a pre-printed web of paper,for cutting such web into one or more discrete sheets for collatingsheets, and for feeding such discrete sheet collations into envelopes.Such equipment may further include components to convey the stuffedenvelopes to a specified location. The industry has long known apparatuswhich accomplish these and other functions. However, improvements areneeded where high volumes of paper piece count and high speeds arerequired without sacrificing reliability accuracy and quality of endproduct.

More particularly, a large roll of paper is typically printed indiscrete areas with piece specific information. That is, the initialroll of paper comprises vast numbers of discrete areas ofalready-printed indicia-specific information with each discrete areadefining what is to eventually comprise a single page or sheet ofindicia specific information. To complicate the process, a variablenumber of sheets with related indicia must be placed into the envelopesso that the content of one envelope varies from the content of anotherby sheet count and, of course, by the specific indicia on the includedsheets. As one example, financial reports of multiple customers oraccount specifics may require a varied number of customer or accountspecific sheets to be cut, respectively collated, stuffed and dischargedfor delivery. Thus, the contents of each envelope include either asingle sheet or a “collation” of from two to many sheets, each“collation” being specific to a mailing to an addressee.

In such an exemplary operation, a financial institution might sendbilling or invoice information to each of its customers. The billinginformation or “indicia” for one customer may require anywhere from onefinal sheet to a number of sheets which must be collated, then placed inthat customer's envelope. While all this information can be printed insheet size discrete areas, on a single roll, these areas must be welldefined, cut, merged or collated into sheets for the same addressee ordestination, placed into envelopes, treated and discharged. Thus, asystem for conducting this process has in the past included certaintypical components, such as a paper roll stand, drive, sheet cutter,merge unit, accumulate or collate unit, folder, envelope feeder,envelope inserter, and finishing and discharge units. Electroniccontrols are used to operate the system to correlate the functions socorrect sheets are collated and placed in correct destination envelopes.

In such multi-component systems, the pass-through rate from paper rollto finished envelope is dependent on the speed of each component, andoverall production speed is a function of the slowest or weakest linkcomponent. Overall reliability is similarly limited. Moreover, the meandown time from any malfunction or failure to repair is limited by themost repair-prone, most maintenance consumptive component. Such systemsare capital intensive, requiring significant floor plan or footprint,and require significant labor, materials and maintenance capabilitiesand facilities.

In such a system, it is sometimes necessary to transport a singlediscreet sheet or a stack of such sheets toward the envelopes as part ofa stuffing operation. In conventional systems of this type, high speedtransportation of the sheets may result in poor control of the sheets asthey travel toward and into the envelopes. Lack of control may, forexample, result in lifting of the sheets away from the plane of travelof the sheets. When a stack of sheets is processed, this lack of controlmay for example further result in the edges of the sheets not beingaligned with one another.

Accordingly, it is desirable to provide an improved transportationapparatus and methods for handling discrete sheets and stacks ofdiscrete sheets in a high speed handling machine. It is also desirableto provide a transportation system and related methods that addressinherent problems observed with conventional paper systems. Moreover, itis desirable to provide a converting apparatus in the form of anautomatic envelope stuffing machine that address the problems ofconventional machines for stuffing envelopes.

SUMMARY

To these ends, in some embodiments, an apparatus transports and guidessingle objects or multiple objects in a stack upwardly to an envelopestuffing position. Drive lugs or fingers engage the trailing edges ofthe objects to move them along while lateral edges of the objects areconfined by guides and while deflectable elements engage and retard theobjects against the drive forces to confine and control the objectspositively as they move along.

More particularly, in one particular embodiment of the invention, anapparatus is provided for transporting a discrete paper or film objectin a machine direction for insertion into an envelope. The apparatusincludes a guide assembly that includes opposed first and secondchannels for guiding the object in the machine direction, with thechannels being oriented upwardly to thereby define an uphill path oftravel for the object. A drive apparatus includes engaging elementsextending transversely to the machine direction for moving the objectalong the first and second channels. At least one support element holdsthe object against the guide assembly.

The at least one support element may include a plurality of deflectableelements for engaging the object. The plurality of deflectable elementsmay include bristles. The deflectable elements may be oriented to applya force on the object in a direction opposite the machine direction asthe object travels in the machine direction. The deflectable elementsmay be arranged to apply a force against the object in a direction thatis transverse to the machine direction during travel of the object inthe machine direction. The engaging elements may be in the form offingers that extend from a plane of travel of the object. The fingersmay be configured to engage a trailing edge of the object to therebymove the object in the machine direction. At least one of the first orsecond channels includes a generally C-shaped profile. The guideassembly may include first and second leg members respectively definingthe first and second channels and including respective distal ends thatare configured to receive the envelope thereon.

The apparatus may include at least one extension element that is coupledto the guide assembly and configured to engage an interior of theenvelope to thereby cause the envelope to open to receive the objecttherein. More particularly, the envelope is moved relative to theextension element to result in the envelope opening by action of theextension element. The extension element may be generally flat. At leastone of the first or second channels may be tapered in the machinedirection. The guide assembly and the drive apparatus may be configuredto move a stack of the objects in the machine direction. The at leastone support element may extend substantially along an entire length ofthe guide assembly.

In another embodiment, an apparatus is provided for transporting adiscrete paper or film object or a stack of such objects in a machinedirection for insertion into an envelope. The apparatus includes a guideassembly that includes opposed first and second leg members, each havingat least a portion thereof including a generally C-shaped channel forguiding the objects in the machine direction. A drive apparatus includesengaging elements for moving the objects along the first and secondchannels. A pair of support elements hold the objects against the guideassembly and include a plurality of deflectable elements for engagingthe object.

In yet another embodiment, an automatic envelope stuffing apparatus isprovided. The apparatus includes a first end associated with feeding ofa roll of paper in a machine direction, and a portion that is configuredto process the roll of paper into discrete paper objects. A second endof the apparatus is associated with feeding of envelopes toward thediscrete objects. A transporting apparatus of the apparatus transportsthe discrete objects towards the envelopes and includes a guide assemblythat has opposed first and second channels for guiding the object in themachine direction, with the channels being oriented upwardly to therebydefine an uphill path of travel for the objects. A drive apparatusincludes engaging elements that extend transversely to the machinedirection for moving the objects along the first and second channels.The transporting apparatus includes at least one support element forholding the objects against the guide assembly.

In another embodiment, a method is provided for transporting a discretepaper or film object or a stack of such objects in a machine directionfor insertion into an envelope. The method includes guiding the objectsin an upward direction and applying a force against a common trailingedge of the objects to move the objects in the machine direction. Themethod may include applying a drag force on the objects during travelthereof in the machine direction. The method may alternatively oradditionally include applying a force on the objects in a direction thatis transverse to the machine direction and transverse to a direction ofgravity for controlling travel of the objects in the machine direction.The method may include restricting movement of the objects in at leastfour directions for controlling travel of the objects in the machinedirection.

Such apparatus and methods are particularly useful in a paper convertingand envelope stuffing system contemplating improved paper converting andsheet inserting apparatus and methods, modular based, and havingimproved paper handling apparatus, servo driven components, improvedsensor density and improved control concepts controlling the systemoperation. One or more of the embodiments of the invention contemplatethe provision of an improved envelope conveying apparatus which can beused as a module of a modular paper converting and sheet insertionsystem where human capital, required space, required equipment,maintenance, labor and materials and facilities therefore are reducedcompared to conventional systems of similar throughput.

More specifically, such improved apparatus and methods contemplate aplurality of functional modules providing the following functions in aseries of modules of like or dissimilar modules where a specific moduleis multi-functional. The functions comprise:

-   -   printed paper roll handling/unwinding;    -   paper slitting and cutting;    -   sheet collation and accumulation;    -   sheet folding;    -   transportation for interfacing with inserts;    -   envelope feeding;    -   collation interfacing and insertion; and    -   envelope treating and discharge.

More particularly, one or more aspects of the invention may contemplate,without limitation, new and unique apparatus and methods for:

-   -   (a) guiding a web of the paper or film containing the printed        indicia into a cutter apparatus;    -   (b) processing the web through slitting and transverse-cutting        operation;    -   (c) transporting and merging discrete pieces of the insert;    -   (d) accumulating predefined stacks of discrete pieces of the        insert;    -   (e) guiding and transporting a stack of discrete pieces of the        insert toward an envelope-filling station;    -   (f) transporting individual envelopes toward the        envelope-filling station;    -   (g) creating and processing a stack of the envelopes prior to        the envelope-filling process; and    -   (h) processing an individual envelope from the stack of        envelopes and through the envelope-filling station.

While the combination of the particular functions in the particularmodules are unique combinations, the invention of this application liesprimarily in the paper transporting apparatus and methods describedherein.

BRIEF DESCRIPTION OF FIGURES

FIG. 1 is a perspective view illustrating a portion of a converter forstuffing envelopes with selected paper or film objects;

FIG. 2 is a perspective view of an interior portion of a transportingapparatus associated with the encircled area of FIG. 1;

FIG. 3 is an elevation view of a portion of a guide assembly of thetransporting apparatus of FIGS. 1-2;

FIG. 4 is a perspective view of a portion of the guide assembly of FIG.3;

FIG. 5 is a view similar to FIG. 2 illustrating a drive apparatus of thetransporting apparatus of FIG. 2;

FIG. 5A is an elevation view of an end portion of the transportingapparatus of FIG. 2 processing an exemplary insert;

FIG. 6 is a view similar to FIG. 5A showing another stage in theprocessing of an exemplary insert; and

FIG. 7 is a view similar to FIG. 6 illustrating processing of an insertdifferent from that shown in FIG. 6.

DETAILED DESCRIPTION

Referring to the figures and, more particularly to FIG. 1, a portion ofan exemplary converter 10 is illustrated for processing a web 12 ofpaper or film. Although not shown, the web 12 processed by the converter10 originates, for example, from a roll (not shown) of materialcontaining such web. The roll is generally associated with a first end14 of the converter 10 and is unwound in ways known in the art, forexample, by driving a spindle receiving a core of the roll or bycontacting a surface of the roll with a belt or similar apparatus.Typically, the web 12 is pre-printed with indicia in discrete areas.

The web 12 thus travels in a machine direction, generally indicated byarrow 15, through several modules that make up the converter 10. In theexemplary embodiment of FIG. 1, converter 10 cuts the web material intodiscrete sheets (corresponding to the “areas”) of material (“inserts”)and feeds them into envelopes fed generally from an opposite end 16 ofconverter 10. Converter 10 may further convey the envelopes containingthe inserts away from the shown portion of the converter 10 forsubsequent processing or disposition. The exemplary converter 10includes, as noted above, several modules for effecting different stepsin the processing of the web and the inserts resulting therefrom, aswell as processing of the envelopes. Those of ordinary skill in the artwill readily appreciate that converter 10 may include other modules inaddition or instead of those shown herein.

A first of the shown modules, for example, is a cutting module 30relatively proximate first end 14 of the converter 10 and which cuts theweb 12 into discrete objects such as inserts (FIG. 2) for subsequentprocessing. A conveying module 40 controls and transports the discreteinserts received from the cutting module and feeds them into a foldingand buffering module 50. Module 50 may, if necessary, form stacks of thediscrete inserts for subsequent processing, for example, if the intendedproduction requires stuffing the envelopes with inserts defined by morethan one discrete sheet. Module 50 folds the discrete inserts, ifrequired by the intended production, along a longitudinal axis of thediscrete inserts disposed generally along the machine direction.Moreover, module 50 accumulates, collates or buffers sets of thediscrete sheets into individually handled stacks, if the particularproduction so requires.

With continued reference to FIG. 1, an uptake module 60 takes theinserts from folding and buffering module 50 and cooperates withcomponents of a stuffing module 70 to transport the inserts and feedthem into envelopes. The envelopes, in turn, are handled and fed towardthe stuffing module 70 by an envelope conveyor 80. A conveying assembly90 is operatively coupled to the stuffing module 70 and the envelopeconveyor 80 for conveying the stuffed or filled envelopes away from theshown portion of converter 10 for subsequent processing or disposition.

With reference to FIGS. 2-6, and particular reference to FIG. 2, aportion of the transporting apparatus 110 of uptake module 60 isillustrated. Uptake module 60 includes a cover or lid 112 (FIG. 1) forlimiting access to moving parts of module 60 and prevent debris and likematerials from depositing on the inserts or envelopes. Transportingapparatus 110 includes a guide assembly 120 extending between first andsecond ends 121, 122 and which has first and second leg members 124, 128in confronting relationship with one another. Guide assembly 120provides a generally curved and uphill path of travel (arrow 130) of thediscrete paper and/or film objects or inserts 131 toward the envelopes132 (FIGS. 3 and 5) generally in the machine direction (arrow 15). Tothis end, each of the leg members 124, 128 includes a respective,lateral guide in the form of a channel 125, 129 that receives one of thelateral edges 131 a of an insert 131 to thereby guide the insert 131 asit travels in the machine direction (arrow 15). Further details ofchannels 125, 129 are discussed in further detail below. As used herein,the term “insert” is intended to cover single discrete sheets of paperor film or a stack of discrete sheets of paper and/or film.

A pair of motors 140 (shown in phantom in FIGS. 2 and 5) permitautomatic adjustment of the spacing between first and second leg members125, 129 in response to a width of the insert 131 and further inresponse to a width of the envelopes 132. In this embodiment, each ofthe motors 140 is operatively coupled to one of the leg members 125,129, for example through jack screws 142 (only one shown in FIG. 5) suchthat turning of shafts of motors 140 result in turning of the jackscrews 142 which, in turn, advances the legs 125, 129 toward oneanother. Alternatively, it is contemplated that only one of the legs125, 129 may be movable toward the other of the legs 125, 129, therebysimilarly automatically adjusting the spacing between them in responseto a width of the insert 131 and in response to a width of the envelopes132. It is also contemplated that a single motor may control both of thelegs 125, 129. Motors 140 may, for example, be stepper motors such asmodel HRA08C available from Sick Stegmann GmbH, a member of the Sick AGGroup of Waldkirch, Germany.

Two support elements 144, 148 cooperate with the guide assembly 120 tohold the inserts 131 against the guide assembly 120 as the inserts 131travel in the machine direction (arrow 15). More specifically, supportelements 144, 148 extend substantially along the entire length L ofguide assembly 120 and are disposed in confronting relationship againstcooperating fixed surfaces 154, 158 of guide assembly 120. Fixedsurfaces 154, 158 similarly extend substantially along the entire length“L” of guide assembly 120.

With continued particular reference to FIG. 2, each of support elements144, 148 includes a plurality of deflectable elements in the form, inthis exemplary embodiment, of bristles 160, diagrammatically illustratedin FIGS. 2 and 5, that engage the inserts 131. In this regard, thesupport elements 144, 148 are positioned, relative to fixed surfaces154, 158, so as to provide a close fit between bristles 160 and thefixed surfaces 154, 158, thereby facilitating guidance of the inserts131. More particularly, the position of support elements 144, 148 issuitably chosen to permit gentle and sturdy engagement of the bristles160 with the inserts 131 (FIGS. 6-7). This engagement results in theexertion of a downward force (arrow 172 of FIGS. 6-7) by the supportelements 144, 148 against the inserts 131. This downward force is in adirection transverse to the machine direction (arrow 15) and transverseto a direction of gravity (arrow 206, for example). Likewise, theengagement of bristles 160 similarly results in the exertion of a dragforce on the inserts 131 e.g., in a direction opposite that of themachine direction (arrow 15), such as that represented by arrow 176 ofFIGS. 6-7. These two forces (arrows 172 and 176 of FIGS. 6-7) cooperateto maintain the inserts 131 against fixed surfaces 154, 158 and therebyguide inserts 131 as they travel in the machine direction (arrow 15)toward the envelopes 132. Accordingly, these two forces minimize liftingor flapping of the inserts 131 as they travel along the length “L” ofguide assembly 120.

While the exemplary embodiment of FIG. 2 includes two support elements144, 148 and two fixed surfaces 154, 158 respectively associated withthe support elements 144, 148, it is contemplated that alternateembodiments may include support elements and cooperating fixed surfacesin any number other than two or include no fixed surfaces at all.Likewise, it is contemplated that fixed surfaces 154, 158 may bereplaced by a suitably chosen structure, so long as it provides aguiding functionality similar to that of transporting apparatus 110.Several braces 180 provide support to each of the support elements 144,148. More particularly, braces 180 provide openings 182 positioned alongthe length “L” of guide assembly 120, for example, to permit structuralcoupling of support elements 144, 148 to a drive apparatus 300 (FIG. 5)of transporting apparatus 110 or other portions (shown in phantom) ofmodule 60.

With continued particular reference to FIG. 2, and with furtherreference to FIGS. 3-4, and as discussed above, leg members 124, 128include respective channels 125, 129 for guiding the inserts 131 as theytravel in the machine direction (arrow 15). For simplicity ofexplanation, details are discussed with reference to only one of the twochannels 125, 129, being understood that the same may apply to one orboth of the channels 125, 129.

Channel 129 extends along a length of leg member 128 and defines openentry and exit ends 129 a, 129 b to respectively receive and dischargethe inserts 131. In this exemplary embodiment, channel 129 includes afunnel or lip section 126 at the entry end 129 a to facilitate receivingthe lateral edges 131 a of inserts 131 (FIG. 3). Channel 129 follows agenerally upward orientation and thus defines a generally uphill path oftravel (arrow 130 of FIG. 5) for the inserts 131 as they travel in themachine direction (arrow 15). In this exemplary embodiment, channel 129tapers in the machine direction (arrow 15) to facilitate preciseguidance of the inserts 131 as they transition from the exit end 129 band into an envelope 132 (FIG. 3). Accordingly, the channel 129 issmaller at its exit end 129 b relative to the entry end 129 a. Morespecifically, in this embodiment, channel 129 tapers from a first widthd₁ to a second width d₂ smaller than the first width d₁.

With continued particular reference to FIGS. 2-4, at least a portion ofchannel 129 has a generally C-shaped cross-section or profile. TheC-shaped profile thus defines a back wall C₁ and opposed top and bottomwalls C₂, C₃ extending from the back wall C₁ for guiding the inserts131. As used throughout the present disclosure, the terms “up,” “down,”“top,” “bottom,” “back,” and derivatives thereof are not intended to belimiting but rather refer to the exemplary orientations shown in thefigures. The C-shaped profile of this exemplary embodiment restrictstravel of the inserts 131 in four directions. More specifically, theback wall C₁ restricts travel of the inserts 131 by providing a stoppingor limiting surface for the edges 131 a of inserts 131. In this regard,therefore, back wall C₁ restricts movement of inserts 131 in a firstdirection (arrow 200 of FIG. 2), while a corresponding back wall C₁ (notshown) of channel 125 restricts movement of inserts 131 in a seconddirection (arrow 202 of FIG. 2) opposite the first direction. Top wallC₂ and bottom wall C₃ of channel 129 restrict movement of the inserts131 respectively upward and downward (arrows 204, 206).

Restriction of movement of the insert 131 in four directions facilitateprecise guidance of inserts 131 as they travel in the machine direction(arrow 15) toward the envelopes 132 (shown in phantom in FIG. 3). Otherstructures of transporting apparatus 110 similarly facilitate guidanceof the inserts 131 into envelopes 132. More particularly, a pair ofgenerally flat extension elements 214, 218 respectively extend from theleg members 124, 128 to facilitate insertion of the inserts 131 into theenvelopes 132. In operation, the flat extension elements 214, 218receive an envelope 132 moving toward them in the direction of arrow220, in such way so as to cause the envelopes 132 to open, therebyexposing the interior of the envelopes 132, as shown in FIG. 3. Theextension elements 214, 218, moreover, maintain the envelope 132 in anopen position during the insertion operation. An exemplary apparatus andmethod for feeding the envelopes 132 toward the extension elements isdisclosed in U.S. patent application Ser. No. 10/553,969, titled “Devicefor Inserting Sheets into an Envelope,” having a filing date of May 12,2003, and the contents of which are herein incorporated by reference inits entirety.

With continued particular reference to FIGS. 2-4, the channel 129 ofthis exemplary embodiment has a generally constant C-shape profile alonga first structural portion 210 of leg member 128. The C-shape profiletapers in the machine direction (arrow 15) along a second structuralportion 211 of leg member 128 that is coupled to the first structuralportion 210. It is contemplated that, alternatively, the entire lengthof channel 129 may be tapered or not be tapered at all. Likewise, it iscontemplated that channel 129 may alternatively extend along anintegrally formed leg member 128, rather than one made up of twostructural portions 210, 211 coupled to one another, as in the exemplaryembodiment of FIGS. 2-4.

Each of the generally flat extension elements 214, 218 of this exemplaryembodiment is respectively integrally formed with the second structuralportions 211 of each of the leg members 124, 128. Accordingly, inoperation, an envelope 132 is pushed so as to surround the exit end 129b of channel 129, as shown in FIG. 3, while simultaneously permittinginsert 131 to be moved in the machine direction (arrow 15) into theinterior of envelope 132.

With continued particular reference to FIGS. 2-4, in this particularembodiment a third extension element is coupled to the guide assembly120 to facilitate guidance of the inserts 131 into envelopes 132. Moreparticularly, a centrally located, generally flat extension element 240is positioned between the extension elements 214, 218, is coupled to anunderside of guide assembly 120, and similarly engages the interior ofenvelopes 132 as these move toward the extension elements 214, 218, 240.While this exemplary embodiment includes two outer extension elements214, 218 and a centrally located extension element 240, it iscontemplated that alternative embodiments may have extension elements ina different number, position, and/or different shapes or have noextension elements at all.

With particular reference to FIGS. 5, 5A, and 6-7, movement of theinserts 131 in the machine direction (arrow 15) is provided by a driveapparatus 300, shown in phantom in FIG. 5, and which engages and movesthe inserts 131. Drive apparatus 300 includes a toothed belt assembly302 rotatable in a closed loop (arrows 303) and driven by a toothedwheel or roller 304 and cooperating rollers 306 disposed so as toposition belt assembly 302 substantially along the entire length “L” ofguide assembly 120. Toothed wheel or roller 304 is supported via a plate307 and fasteners 308 from a main frame 309 of transporting apparatus110. Toothed wheel or roller 304 is similarly coupled, via plate 307, toeach of the support elements 144, 148 such that drive apparatus 300 andthe support elements 144, 148 can be lifted simultaneously away fromguide assembly 120. Drive apparatus 300 includes a plurality of fingers310 spaced along the length of the belt assembly 302 and extendingtherefrom to engage the trailing edges 131 s of the inserts 131.

With particular reference to FIGS. 5-5A, fingers 310 are arranged inpairs such that the inserts 131 may be engaged at two points (only oneshown in FIG. 5A) along the trailing edges 131 s of the inserts 131 asthey travel in the machine direction (arrow 15). In this regard, driveapparatus 300 is also positioned such that the fingers 310 penetrateopen spaces 314 (FIG. 5) between the extension element 240 and the fixedsurfaces 154, 158, thereby providing stopping or limiting surfacesagainst which the trailing edges 131 s of the inserts abut. Inoperation, as the inserts 131 travel in the machine direction (arrow 15)guided by the guide assembly 120, the drag and downward forces (arrows172 and 206 of FIG. 2) retard the inserts 131 against the fingers 310such that stacked individual sheets making up an insert 131 becomealigned with one another along their respective trailing edges 131 s, asillustrated in FIG. 5A. Accordingly, the fingers 310 facilitateinsertion of a stack of sheets in alignment or registration with oneanother. Once the insert 131 is inserted into the envelope 132, theresulting stuffed envelope is taken away by components such as, forexample, rollers R₁ and R₂ (shown in phantom) of an envelope feedingand/or conveying apparatus for further disposition.

With particular reference to FIGS. 5 and 6, a feature of the exemplarydeflectable elements in the form of bristles 160 is illustrated.Bristles 160 are shown deflecting to accommodate the thickness ofinserts 131. Accordingly, FIG. 5 shows the bristles 160 deflecting to afirst degree associated with a first thickness t₁ of an insert 131. FIG.4 shows the bristles 160 deflecting to a second degree associated with asecond thickness t₂ of an insert 131 larger than the first thickness t₁.

As used herein, the term “deflectable elements” refer to solidstructures that flex in reaction to a force exerted upon them. In thisregard, while the deflectable elements of the embodiment of FIGS. 2-7are in the form of bristles 160, it is contemplated that the deflectableelements could alternatively take on other forms, so long as theyprovide at least some of the functionality described in this disclosure.For example, and without limitation, these could take the form offlexible flaps or other structures.

While the present invention has been illustrated by a description ofvarious embodiments and while these embodiments have been described inconsiderable detail, it is not intended to restrict or in any way limitthe scope of the appended claims to such detail. Additional advantagesand modifications will readily appear to those skilled in the art. Theinvention in its broader aspects is therefore not limited to thespecific details, representative apparatus and method, and illustrativeexample shown and described. Accordingly, departures may be

1. An apparatus for transporting a discrete paper or film object in amachine direction for insertion into an envelope, comprising: a guideassembly including opposed first and second channels for guiding theobject in the machine direction, said channels being oriented upwardlythereby defining an uphill path of travel for the object; a driveapparatus including engaging elements extending transversely to themachine direction for moving the object along said first and secondchannels; and at least one support element for holding the objectagainst said guide assembly.
 2. The apparatus of claim 1, wherein saidat least one support element includes a plurality of deflectableelements for engaging the object.
 3. The apparatus of claim 2, whereinsaid plurality of deflectable elements include bristles.
 4. Theapparatus of claim 2, wherein said deflectable elements are arranged toapply a force on the object in a direction opposite the machinedirection as the object travels in the machine direction.
 5. Theapparatus of claim 2, wherein said deflectable elements are oriented toapply a force against the object in a direction transverse to themachine direction during travel of the object in the machine direction.6. The apparatus of claim 1, wherein said engaging elements are in theform of fingers extending from a plane of travel of the object.
 7. Theapparatus of claim 6, wherein said fingers are configured to engage atrailing edge of the object to thereby move the object in the machinedirection.
 8. The apparatus of claim 1, wherein at least one of saidfirst or second channels includes a generally C-shaped profile.
 9. Theapparatus of claim 1, wherein said guide assembly includes first andsecond leg members respectively defining said first and second channelsand including respective distal ends configured to receive the envelopethereon.
 10. The apparatus of claim 9, further comprising: at least oneextension element coupled to said guide assembly and configured toengage an interior of the envelope to thereby cause the envelope to opento receive the object therein.
 11. The apparatus of claim 10, whereinsaid at least one extension element is generally flat.
 12. The apparatusof claim 1, wherein at least one of said first or second channels istapered in the machine direction.
 13. The apparatus of claim 1, whereinsaid guide assembly and said drive apparatus are configured to move astack of the objects in the machine direction.
 14. The apparatus ofclaim 1, wherein said at least one support element extends substantiallyalong an entire length of said guide assembly.
 15. The apparatus ofclaim 1, wherein said guide assembly includes first and second legmembers respectively defining said first and second channels, furthercomprising a motor operatively coupled to at least one of said first andsecond leg members for automatically moving said at least one of saidfirst and second leg members toward the other of said first and secondleg members in response to a width of the envelope.
 16. The apparatus ofclaim 15, wherein said motor is operatively coupled to said first andsecond leg members for moving both of said first and second leg memberstoward one another.
 17. An apparatus for transporting a discrete paperor film object or a stack of such objects in a machine direction forinsertion into an envelope, comprising: a guide assembly includingopposed first and second leg members each having at least a portionthereof including a generally C-shaped channel for guiding the objectsin the machine direction; a drive apparatus including engaging elementsfor moving the objects along said first and second channels; and a pairof support elements for holding the objects against said guide assemblyand including a plurality of deflectable elements for engaging theobject.
 18. An automatic converting apparatus having a first endassociated with feeding of a roll of paper in a machine direction, aportion configured to process the roll of paper into discrete paperobjects, and a second end associated with feeding of envelopes towardthe discrete objects, the converting apparatus further comprising: atransporting apparatus for transporting the discrete objects toward theenvelopes and including: a guide assembly including opposed first andsecond channels for guiding the objects in the machine direction, saidchannels being oriented upwardly thereby defining an uphill path oftravel for the objects; a drive apparatus including engaging elementsextending transversely to the machine direction for moving the objectsalong said first and second channels; and at least one support elementfor holding the objects against said guide assembly.
 19. A method oftransporting a discrete paper or film object or a stack of such objectsin a machine direction for insertion into an envelope, comprising:guiding the objects in an upward direction; and applying a force againsta common trailing edge of the objects to move the objects in the machinedirection.
 20. The method of claim 19, further comprising: applying adrag force on the objects during travel thereof in the machinedirection.
 21. The method of claim 19, further comprising: applying aforce on the objects in a direction transverse to the machine directionfor controlling travel of the objects in the machine direction.
 22. Themethod of claim 19, further comprising: restricting movement of theobjects in at least four directions for controlling travel of theobjects in the machine direction.
 23. The method of claim 19, furthercomprising: automatically adjusting a distance between lateral guidesengaging lateral edges of the objects in response to a width of theenvelope.
 24. The method of claim 19, further comprising: aligningrespective trailing edges of objects in a stack relative to one anotherduring travel of the stack in the machine direction.